Satellite deployer with composite guide rail

ABSTRACT

A satellite dispenser is disclosed. In various embodiments, a satellite dispenser as disclosed herein includes a dispenser body defining an interior cavity configured to receive a payload; and a composite guide rail comprising a groove configured to receive at least a portion of a payload, the composite guide rail having an orientation that substantially aligns a longitudinal axis of the groove with an ejection axis of the dispenser.

CROSS REFERENCE TO OTHER APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/051,268, entitled SATELLITE DEPLOYER WITH COMPOSITE GUIDE RAIL filedJul. 31, 2018 which is incorporated herein by reference for allpurposes, which claims priority to U.S. Provisional Application No.62/541,493, entitled SMALL SCALE SATELLITE DEPLOYER filed Aug. 4, 2017which is incorporated herein by reference for all purposes.

GOVERNMENT LICENSE RIGHTS

This invention was made with Government support under Contract No.2014-14031000011 awarded by a United States Government Agency. TheUnited States Government has certain rights in the invention.

BACKGROUND OF THE INVENTION

Small scale satellites, such as CubeSat or other small satellites, maybe launched into space in a launch vehicle that includes a plurality ofsuch satellites, each contained in a “dispenser” device, sometimesreferred to as a small scale satellite “deployer”, configured to deploythe small scale satellite in a controlled manner, e.g., to achieve atarget orbit. The terms “dispenser” and “deployer” are usedinterchangeably in this specification.

Satellites conforming to the CubeSat Design Specification may have asize and form factor of a corresponding type or class of CubeSat asdefined by the standard. The size and form factor of a CubeSat is basedon a standard 10×10×11.35 cm3 unit designed to provide 10×10×10 cm3 (or1 liter) of useful volume. CubeSats of different types may comprise adifferent number of such units. For example, CubeSats comprising 1, 3,6, or 12 units, sometimes designated as 1U, 3U, 6U, and 12U CubeSats,respectively, may be encountered. Other satellites comprising otherwhole or fractional numbers of standard units may be launched anddeployed.

Small scale satellite dispensers typically have a shape, size, and formfactor to accommodate a corresponding small scale satellite, andcommonly have a door that provides access to a payload area of thedispenser. The small scale satellite (payload) is loaded into thedispenser through the opening associated with the door, with the door inthe open position. The door is closed and secured in the closedposition. The dispenser may be arranged with other dispensers in achassis configured to accommodate multiple dispensers. The chassis isloaded into a launch vehicle, such as a rocket, and launched into space.Control circuits initiate deployment of the small scale satellite at atime, orientation, etc. associated with the target orbit of eachrespective small scale satellite. Typically, a satellite is deployed bycausing the dispenser door to open at a precise time, resulting in thesmall scale satellite being ejected from the dispenser and into orbit.Solar panels, antennae, and other appendages and auxiliary equipment mayopen, extend, or otherwise deploy once the small scale satellite hasbeen ejected from the dispenser.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention are disclosed in the followingdetailed description and the accompanying drawings.

FIG. 1A is a diagram illustrating an embodiment of a small scalesatellite dispenser.

FIG. 1B is a diagram illustrating an embodiment of the small scalesatellite dispenser 100 of FIG. 1A with the door 104 open.

FIG. 1C is a diagram illustrating an embodiment of the small scalesatellite dispenser 100 of FIG. 1A with the door 104 open and thepayload 106 ejected from the payload area defined by dispenser body 102.

FIG. 2A is a diagram illustrating an embodiment of a small scalesatellite dispenser provided with a pyrotechnic cutter door releasemechanism prior to cutter activation.

FIG. 2B is a diagram illustrating an embodiment of a small scalesatellite dispenser provided with a pyrotechnic cutter door releasemechanism after cutter activation.

FIG. 3A is a diagram illustrating an embodiment of a composite guiderail and a mold to fabricate same.

FIG. 3B is a diagram illustrating an embodiment of a satellite dispenserwith composite guide rails.

FIG. 4A is a diagram illustrating an embodiment of a satellite dispenserpusher plate assembly.

FIG. 4B is a diagram illustrating front and side views of the satellitedispenser pusher plate assembly 400 of FIG. 4A.

FIG. 5A is a diagram illustrating a front view of an embodiment of asatellite dispenser with composite guide rails.

FIG. 5B is a diagram illustrating additional elements of the satellitedispenser with composite guide rails of FIG. 5A.

FIG. 5C is a diagram illustrating additional elements of the satellitedispenser with composite guide rails of FIG. 5A.

FIG. 5D is a diagram illustrating the satellite dispenser with compositeguide rails of FIGS. 5A, 5B, and 5C with a satellite payload inserted.

DETAILED DESCRIPTION

The invention can be implemented in numerous ways, including as aprocess; an apparatus; a system; a composition of matter; a computerprogram product embodied on a computer readable storage medium; and/or aprocessor, such as a processor configured to execute instructions storedon and/or provided by a memory coupled to the processor. In thisspecification, these implementations, or any other form that theinvention may take, may be referred to as techniques. In general, theorder of the steps of disclosed processes may be altered within thescope of the invention. Unless stated otherwise, a component such as aprocessor or a memory described as being configured to perform a taskmay be implemented as a general component that is temporarily configuredto perform the task at a given time or a specific component that ismanufactured to perform the task. As used herein, the term ‘processor’refers to one or more devices, circuits, and/or processing coresconfigured to process data, such as computer program instructions.

A detailed description of one or more embodiments of the invention isprovided below along with accompanying figures that illustrate theprinciples of the invention. The invention is described in connectionwith such embodiments, but the invention is not limited to anyembodiment. The scope of the invention is limited only by the claims andthe invention encompasses numerous alternatives, modifications andequivalents. Numerous specific details are set forth in the followingdescription in order to provide a thorough understanding of theinvention. These details are provided for the purpose of example and theinvention may be practiced according to the claims without some or allof these specific details. For the purpose of clarity, technicalmaterial that is known in the technical fields related to the inventionhas not been described in detail so that the invention is notunnecessarily obscured.

A satellite dispenser with composite guide rails is disclosed. Invarious embodiments, a dispenser as disclosed herein may include in eachof four interior corners a guide rail. The guide rail may comprise acomposite/laminate structure. An interior glide surface of the rail(s)may be impregnated with silicon carbide or another hard material. Theguide rails may be carbon composite laminates that conform to the shapeof the dispenser along an associated dimension of the dispenser, such asthe longitudinal satellite insertion/ejection axis of the dispenser,e.g., to utilize the minimum amount of material to save costs and toprovide a rigid backbone for the structure.

In various embodiments, the rails are carbon composite rails with alayer of silicon carbide on the payload dispenser interface. The siliconcarbide provides a very hard and smooth surface for the CubeSat rails tointerface with. In some embodiments, the silicon carbide layer is laidright on top of the carbon fiber laminate layers during the fabricationprocess.

In various embodiments, a dispenser as disclosed herein includes apusher plate assembly inside the dispenser at an end opposite the door.A payload loaded into the dispenser pushes against the pusher plate,compressing a main spring of the pusher plate assembly. When thedispenser door is released, the spring extends exerting force thatpushes the payload out of the dispenser.

In some embodiments, a protrusion or other structure of a pusher platerides inside the central groove or valley of a guide rail as disclosedherein. In some embodiments, the pusher plate includes such a protrusionat each of its four corners to maintain alignment with respect tointernal guide rails. The protrusion may include or be covered by acover or insert comprising durable low friction material, such asTeflon™.

FIG. 1A is a diagram illustrating an embodiment of a small scalesatellite dispenser. In the example shown, dispenser 100 includes adispenser casing or body 102 with a door 104 at one end. In the stateshown in FIG. 1A, the dispenser door 104 is closed, as it would besubsequent to a small scale satellite being loaded into the dispenser100 but before deployment.

FIG. 1B is a diagram illustrating an embodiment of the small scalesatellite dispenser 100 of FIG. 1A with the door 104 open. A small scalesatellite 106 is visible in the payload area defined by dispenser body102. The state shown in FIG. 1B may be associated with loading thepayload 106 into the dispenser 100, but prior to the door 104 beingclosed, and/or just prior to ejection of payload 106 after the door 104being opened.

FIG. 1C is a diagram illustrating an embodiment of the small scalesatellite dispenser 100 of FIG. 1A with the door 104 open and thepayload 106 ejected from the payload area defined by dispenser body 102.In various embodiments, the payload 106 may have been ejected at leastin part by a spring-loaded pusher plate against which the payload 106had been pressed against during loading of payload 106 into dispenser100, thereby compressing one or more springs associated with the pusherplate.

In various embodiments, the state of dispenser 100 as shown in FIGS. 1Band 1C is attained at least in part by activating a door releasemechanism (not shown in FIGS. 1A through 1C) configured to hold door 104in the closed position prior to activation. Upon activation of the doorrelease mechanism, the door 104 is no longer held in the closedposition. In various embodiments, one or more springs compressed byclosing door 104 and securing door 104 in the closed position may, uponactivation of the door release mechanism, cause the door 104 to bepushed open, as in FIGS. 1B and 1C, allowing the payload 106 to beejected, as shown in FIG. 1C.

FIG. 2A is a diagram illustrating an embodiment of a small scalesatellite dispenser provided with a pyrotechnic cutter door releasemechanism prior to cutter activation. In the example shown, satellitedispenser 200 includes a dispenser body 202 and door 204. The door 204is held closed in the state shown by a door release mechanism 206 whichin this example includes a wire or cable (not shown in FIG. 2A) to holdthe door closed prior to deployment and two pyrotechnic cutterspositioned and configured to cut the wire or cable to release the door204 to enable the door 204 to open. In the example shown, electricalleads 208 are connected to the pyrotechnic cutters included in doorrelease mechanism 206. In various embodiments, signals and/or power toactivate the pyrotechnic cutters is/are provided via leads 208, e.g.,from a driver or similar component comprising and/or otherwiseassociated with the dispenser 200.

FIG. 2B is a diagram illustrating an embodiment of a small scalesatellite dispenser provided with a pyrotechnic cutter door releasemechanism after cutter activation. In the state shown in FIG. 2B, thepyrotechnic cutters comprising door release mechanism 206 have beenfired resulting in the cable or wire holding door 204 closed being cut.In the example shown, the door 204 has been assisted in opening by aspring-loaded pusher 210 being pushed out from the door releasemechanism 206 once the wire or cable holding the door 204 shut had beencut. Also shown in FIG. 2B is a recess or cavity 212 into which a doorside portion of the wire or cable that had been holding the door 204closed has been pulled, e.g., by a spring-loaded plunger configured toextend into the cavity 212 pulling the door end of the cut wire or cableinto cavity 212. In various embodiments, the wire or cable retractionmechanism configured to pull the free end of the cut wire or cable intocavity 212 ensures the loose (door) end of the cut wire or cable doesnot interfere with ejection and/or deployment of the small scalesatellite from dispenser 200.

FIG. 3A is a diagram illustrating an embodiment of a composite guiderail and a mold to fabricate same. In the example shown, layers 302 ofcarbon (or other) fiber reinforced fabric that has been pre-impregnatedwith a resin system, such as epoxy, are laid up on a mold 304. Mold 304may be made of machined aluminum or another durable material withpredictable thermal expansion behaviors for the elevated temperature atwhich the composite guide rail is cured.

In various embodiments, to form a composite guide rail as disclosedherein, the mold 304 is polished, laminate layers 302 are laid on top,the layers 302 are topped with a peel-ply perforated release film andbreather material, and the assembly 302, 304 is placed in a vacuum bag.Once the mold 304 and laminate 302 are sealed in the vacuum bag, the bagis purged of all gasses with a vacuum pump. The assembly 302, 304 iscured in a high pressure, high temperature autoclave for the specifiedtime required by the pre-preg laminates 302.

In various embodiments, composite guide rails as disclosed herein may becarbon composite rails with a layer of silicon carbide on the payloaddispenser interface. The silicon carbide provides a very hard and smoothsurface for the CubeSat rails to interface with. In some embodiments, asilicon carbide layer is laid right on top of the carbon fiber laminatelayers (e.g., layers 302 in FIG. 3A) during the fabrication process.

FIG. 3B is a diagram illustrating an embodiment of a satellite dispenserwith composite guide rails. In the example shown in FIG. 3B, a finishedcomposite guide rail is shown in positions at the four corners of thesatellite dispenser payload chamber (of the dispenser body, not shown inFIG. 3B. In various embodiments, the four corners of the payload 320,e.g., CubeSat rails or other small scale satellite corner/edgestructures, engage and ride on the inner guide defined by the centrallobe of the guide rail 302. In various embodiments, the silicon carbidelayer on the side of guide rails 302 that face and engage the payload320 enables the payload 320 to slide more freely along the guide rails302, e.g., during satellite ejection and deployment.

FIG. 4A is a diagram illustrating an embodiment of a satellite dispenserpusher plate assembly. In the example shown, pusher plate assembly 400includes a pusher plate 402 coupled to a dispenser end plate or panel404 by a spring 406. In various embodiments, a satellite loaded into adispenser that includes pusher plate assembly 400 is pressed against thepusher plate 402, comprising spring 406, enabling the dispenser door tobe closed. Upon release of the dispenser door to eject and deploy thesatellite, the spring 406 extends and pushes pusher plate 402 in thedirection of the dispenser door opening, which in turn pushes thesatellite, riding on one or more guide rails, such as guide rails 302 ofFIGS. 3A and 3B, out and through the dispenser door opening.

FIG. 4B is a diagram illustrating front and side views of the satellitedispenser pusher plate assembly 400 of FIG. 4A. As shown in FIG. 4B, thepusher plate 402 includes protrusions 410, 412, 414, and 416 atlocations on pusher plate 402, each of which aligns, in variousembodiments, with a corresponding groove comprising a guide rail (e.g.,guide rail 302) positioned in an interior corner of a dispenser payloadarea.

In the example shown, protrusions 410, 412, 414, and 416 are formed asan integral part of the pusher plate 402 and extend back towards the endplate as tapered posts, the distal ends of which engage, when thedispenser is loaded and spring 406 is compressed, with correspondingnylon (or other polymer0 adjustable “feet”, represented in FIG. 4B byfeet 420 and 422. Each of the tapered posts comprising the fourprotrusions (410, 412, 414, 416) aligns opposite a corresponding one ofthe feet. Each of the feet (e.g., 420, 422) is adjustable in its extentinto the payload area of the dispenser and/or the force applied to thepusher plate 402 via the protrusion 410, 412, 414, and 416 with which itis aligned by an adjustment screw (or similar structure), represented inFIG. 4B by adjustment screws 424 and 426. In various embodiments, thenylon (or other) feet 422, 424 and associated adjustment screws 424, 426are torqued to a prescribed torque to secure the payload firmly in thepayload area, e.g., to avoid movement during flight, which could damagethe satellite.

In various embodiments, the tapered profile of the posts comprisingprotrusions 410, 412, 414, and 416 ensure the pusher plate 402 remainsaligned properly within the dispenser and glides smoothly along theguide rails 302.

FIG. 5A is a diagram illustrating a front view of an embodiment of asatellite dispenser with composite guide rails. In the example shown,the alignment of the pusher plate 402 and associated protrusions withthe corresponding grooves defined by guide rails 302 is illustrated. Invarious embodiments, the corner protrusions of pusher plate 402 fitwithin the central groove of the guide rails 302 within a tolerance thatensures the pusher plate 402 slides along the guide rails 302 duringpayload ejection with minimal rotation about the longitudinal or x axisof the dispenser, which could impart undesired rotation on the payloadas it is ejected.

FIG. 5B is a diagram illustrating additional elements of the satellitedispenser with composite guide rails of FIG. 5A. In the example shown,side panels 502 have been bonded (e.g., adhesively) to the guide rails302 as shown in FIG. 5A.

In various embodiments, the side panels 502 are made of carbon fiberreinforced polymer composites with phenolic impregnated aramid honeycombcores sandwiched in the middle. The sandwich core may be a 1/16th inchthick aramid honeycomb that provides rigidity to the carbon compositeskins. Honey comb layer is laid up between the carbon fiber during thelayup process and is cured with the skins in place. In some embodiments,the sandwich core is a ⅛th inch thick aluminum honeycomb that providesrigidity to the carbon composite skins. The honeycomb core is perforatedto allow excess gasses to escape, preventing the honeycomb cells fromcollapsing due to excessive pressures.

In some embodiments, access ports are cut out from the panels and postprocessed with additional carbon fiber patches to cover the exposedhoney comb edges. Threaded inserts are then epoxied into the skin toprovide mounting points for the access port panels. The panels are cutand bent sheet metal aluminum that are lightweight and low cost tomanufacture.

FIG. 5C is a diagram illustrating additional elements of the satellitedispenser with composite guide rails of FIG. 5A. In the example shown,corner pieces 504 have been bonded to the side panels 502. In variousembodiments, the outer corner pieces are simple carbon compositelaminates that conform to the shape of the end frames. In someembodiments, the corner pieces 504 help to provide a rigid backbone forthe dispenser body structure.

FIG. 5D is a diagram illustrating the satellite dispenser with compositeguide rails of FIGS. 5A, 5B, and 5C with a satellite payload inserted.In the example shown, a payload 510 has been inserted into the dispenserand press against the pusher plate 402. As shown, the four corners(e.g., CubeSat rails) of payload 510 engage the grooves defined by andride on the inner surface of the guide rails 302.

In various embodiments, a small scale satellite dispenser as disclosedherein is fabricated at least in part by bonding sides to compositeguide rails, as in FIG. 5B; adding corner pieces, as in FIG. 5C;installing at one end of the resulting assembly a pusher plate assemblythat includes an end plate or panel, as in FIGS. 4A and 4B; andinstalling at the opposite end a door assembly, e.g., as shown in FIGS.2A and 2B.

In various embodiments, a dispenser with composite guide rails asdisclosed herein provides reliable deployment with minimum weight andcost of materials.

Although the foregoing embodiments have been described in some detailfor purposes of clarity of understanding, the invention is not limitedto the details provided. There are many alternative ways of implementingthe invention. The disclosed embodiments are illustrative and notrestrictive.

What is claimed is:
 1. A satellite dispenser, comprising: a dispenserbody defining an interior cavity configured to receive a payload,wherein the dispenser body comprises: one or more sides, the one or moresides respectively comprising a carbon fiber reinforced polymercomposite and a honeycomb core; and a plurality of composite guide railsrespectively comprising a groove configured to receive at least aportion of the payload, wherein: each of plurality of composite guiderails has an orientation that substantially aligns a longitudinal axisof the groove with an ejection axis of the dispenser; each of theplurality of composite guide rails is comprised in a respective cornerof the dispenser body; an exterior profile of the composite guide railis enclosed within the dispenser body; and the composite guide rail ismounted within the dispenser body.
 2. The satellite dispenser of claim1, wherein the composite guide rail is included in a set of fourcomposite guide rails, and each guide rail located at a correspondingedge of the interior cavity.
 3. The satellite dispenser of claim 1,wherein the composite guide rail defines in part the interior cavity. 4.The satellite dispenser of claim 1, wherein the dispenser comprises fourcomposite guide rails arranged in a rectangular array and the dispenserbody comprises four side panels each bonded to two adjacent ones of thecomposite guide rails.
 5. The satellite dispenser of claim 1, whereinthe composite guide rail comprises a silicon carbide layer at apayload-facing outer layer of the composite guide rail.
 6. The satellitedispenser of claim 1, further comprising a pusher plate assembly at anend of the dispenser opposite a door opening of the dispenser body,wherein the pusher plate assembly includes a pusher plate comprising aprotrusion that extends at least in part into the groove of thecomposite guide rail.
 7. The satellite dispenser of claim 6, wherein thegroove of the composite guide rail substantially aligns the pusher plateto traverse the longitudinal axis of the groove in connection withejecting the payload from the dispenser body.
 8. The satellite dispenserof claim 6, wherein the dispenser includes four composite guide rails,each at a corresponding location within the interior cavity, and thepusher plate includes four protrusions, each extending at least in partinto the respective groove of a corresponding one of the composite guiderails.
 9. The satellite dispenser of claim 1, wherein the compositeguide rail is fabricated at least in part by laying up layers ofpre-impregnated carbon or other fiber reinforced fabric on a mold havinga shape associated with the composite guide rail.
 10. The satellitedispenser of claim 9, wherein the mold defines the groove of thecomposite guide rail.
 11. The satellite dispenser of claim 1, whereinthe composite guide rail comprises substantially orthogonal outerflanges joined by central lobe that defines the groove.
 12. Thesatellite dispenser of claim 11, wherein each of the outer flanges isbonded to an associated side panel comprising the dispenser body. 13.The satellite dispenser of claim 1, wherein the composite guide railcomprises carbon composite laminates.
 14. The satellite dispenser ofclaim 13, wherein the carbon composite laminates have a profile thatconforms to a shape of the dispenser along the ejection axis of thedispenser.
 15. The satellite dispenser of claim 1, wherein the compositeguide rail comprises a silicon carbide.
 16. The satellite dispenser ofclaim 15, wherein: the composite guide rail further comprises aplurality of layers comprising carbon fibers; the silicon carbide isdisposed on top of the plurality of layers; and the silicon carbideforms a surface that interfaces with a rail on the payload, wherein therail on the payload forms at least part of a profile of the payload. 17.The satellite dispenser of claim 16, wherein: the satellite dispenserfurther comprises one or more side panels; and the one or more sidepanels comprise carbon fiber reinforced polymer composites.
 18. Thesatellite dispenser of claim 17, wherein: the honeycomb core comprisesphenolic impregnated aramid honeycomb cores.
 19. The satellite dispenserof claim 1, wherein the honeycomb core comprises an aluminum honeycomb.20. The satellite dispenser of claim 1, wherein the dispenser body has arectangular profile, and the plurality of composite guide railscomprises four guide rails respectively disposed in the four corners ofthe inner cavity of the dispenser body.
 21. The satellite dispenser ofclaim 1, wherein each of the plurality of composite guide railscomprises a cross-sectional geometry that defines the groove, and thegroove is configured to receive a corner of the payload.
 22. Thesatellite of dispenser of claim 1, further comprising a pusher plate,wherein the pusher plate pushes the payload to a front side of thesatellite dispenser to eject the payload, and the pusher plate comprisesa plurality of protrusions, and each of the protrusions is configured toextend into the groove of a corresponding composite guide rail.